Laser-Welded Acoustic Panel Assembly Without Element Deformation
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing acoustic attenuation panels face challenges in effectively treating low frequencies without using thick multicellular bodies, and conventional assembly methods risk deforming hollow acoustic elements, leading to reduced acoustic performance due to adhesive intrusion or heat-induced deformation.
Innovation Solution
A method involving laser welding of hollow acoustic elements to an opaque acoustic skin using thermoplastic materials with controlled laser wavelengths, ensuring precise attachment and minimizing deformation risks.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If adhesive is used to assemble hollow acoustic elements with acoustic skin, then assembly is simple, but adhesive may fall inside hollow elements altering acoustic performance
Solution Approach 1:
The patent replaces adhesive bonding with laser welding to join the acoustic skin to the hollow acoustic elements. This substitution eliminates the risk of adhesive intrusion into the hollow elements while maintaining strong assembly. The laser welding process uses a laser beam to melt and fuse the thermoplastic materials at the contact interface, providing a clean, precise join without contaminating the acoustic elements.
Solution Approach 2:
The laser welding process utilizes phase transitions of the thermoplastic materials. The laser beam heats the contacting surfaces of the acoustic skin and hollow acoustic elements to their melting point, causing localized melting. Upon cooling, the materials solidify and form a strong weld joint. This phase change mechanism enables reliable assembly without adhesive contamination.
2Strength
If conductive welding is used to assemble hollow acoustic elements with acoustic skin, then strong bonding is achieved, but heat deforms hollow elements deteriorating acoustic performance
Solution Approach 1:
The patent replaces conductive welding with laser welding. Unlike conductive welding which distributes heat through contact, laser welding concentrates energy at the precise contact interface between the acoustic skin and hollow elements. This localized heating minimizes thermal diffusion to adjacent areas, preventing deformation of the hollow elements while achieving strong bonding at the weld zone.
Solution Approach 2:
The laser welding process applies heat locally only at the contact interface between the acoustic skin and hollow acoustic elements. The high energy density of the laser beam creates a localized melt zone precisely where joining is needed, without significantly heating surrounding areas. This local quality approach maintains the dimensional accuracy and shape of the hollow elements while providing strong localized bonding.
3Reliability
If thinner hollow acoustic elements are used, then acoustic performance improves, but deformation risk under heat increases
Solution Approach 1:
The patent uses laser welding instead of conductive welding to join thin-walled hollow acoustic elements. The laser beam delivers concentrated energy directly to the contact interface, creating a small, localized heat-affected zone. This minimizes thermal exposure of the thin walls, preventing deformation while achieving reliable bonds. The process is particularly suitable for thin-walled elements where conventional heating methods would cause excessive thermal distortion.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method effectively assembles hollow acoustic elements to the skin without adhesive intrusion, maintaining acoustic performance by reducing deformation and ensuring precise alignment and attachment.
Implementation Method 1
emitting a laser beam having the determined wavelength and passing through the connecting edges until it reaches the contact interface between the connecting edges and the acoustic skin such as to cause localised heating at said contact interface resulting in welding
Implementation Method 2
the acoustic skin is made of a thermoplastic material that is opaque for at least the determined laser wavelength
Implementation Method 3
cause localised heating at said contact interface resulting in welding of the connecting edges to the acoustic skin
Data Source
AI summary
A method for manufacturing an acoustic panel includes the assembly of at least one acoustic component with an acoustic skin, the acoustic component including a plurality of hollow acoustic elements having a shape progressively tapering between a base and an apex, the bases of the hollow acoustic elements being connected to one another by connecting edges, wherein the connecting edges of the acoustic component are made of a transparent thermoplastic material and wherein the acoustic skin is made of an opaque thermoplastic material, and the connecting edges are attached to the acoustic skin by laser welding.